Damage analysis with FEM, CFD & multiphysics
Understanding causes, preventing damage, increasing operational safety
When components or machines fail prematurely, high costs arise—not only for replacement parts or repairs, but also for production downtime, stoppages, and, in the worst case, recalls. Therefore, in the event of damage, it is important to develop a solution professionally, quickly, and purposefully in order to minimize consequential damage and maintain your customers' trust in you.
Damage analysis is not just about documenting a defect—it is crucial to understand the physical causes and use this knowledge to derive safe optimizations.
Traditional approaches often reach their limits here, as complex load cases, thermal effects, and flow influences are difficult to verify. This is precisely where numerical methods come into play: we use the finite element method (FEM) to analyze stresses, deformations, and fracture mechanisms. Computational fluid dynamics (CFD) provides precise insights into flows, temperature, and pressure fields. In many cases, both phenomena interact – multiphysics simulations capture these interactions realistically.
Much damage could have been identified and thus avoided during the development phase using numerical simulations. We help you to quickly verify damage, avoid repetition, and increase the safety of your products.
This provides you with a valid basis for decision-making, minimizes follow-up costs, and sustainably increases the operational safety of your products.
Initial assessment Secure damage analysis
Damage analysis for components and machines
Merkle CAE Solutions supports you from the initial analysis to optimization and verification—all from a single source. We use FEM and CFD simulations to make complex causes of damage transparent. This not only provides valuable insights—from design to final assembly—but also saves a tremendous amount of time. Damage analyses are often long-term processes. Simulation technologies can shorten the time required to gain insights many times over.
Our services at a glance:
Investigation and determination of the cause of damage
Simulation of damage occurrence
Evaluation of possible repair measures
Optimization of component structure for new designs
Verifiable strength verification after optimization
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Practical examples
Thermomechanical stresses caused cracks in weld seams in a dryer. This was confirmed by calculations, and the stresses were reduced sustainably following redesign and optimization.
Cracks appeared on an axle connection of a dryer due to an unaccounted load case. Adjusting the operating conditions allowed continued operation until replacement.
Resonance frequencies caused breaks in the grounding contacts of rail vehicles. Structural measures were taken to safely shift the natural frequencies.
Leakage was detected in a complex seal geometry for a rotary valve. The seal and corresponding connecting components were examined in an FE analysis. This revealed that the end components were too soft and the contact pressure too low. After adjusting the geometry, tightness could be guaranteed.
Cracks in the baffle plate of a ventilation duct due to vortex shedding at the natural frequency of the baffle plate. The cause of the damage was verified mathematically using a coupled multiphysics simulation. The baffle plate was then modified so that the flow no longer excites the baffle plate at its natural frequency.
Dry running of shaft bearings in a gearbox was observed, particularly when cornering. CFD simulation was used to recreate the damage and optimize the oil supply accordingly.
Damage analysis with Merkle CAE
Your advantages with Merkle CAE Solutions
Get an experienced partner at your side who masters the entire damage analysis process—from inventory and simulation to optimization. As experts in multiphysics simulation, we can tackle almost any scenario in engineering simulation. Not only in conventional areas, but also in modern or high-tech fields:
Your advantages:
Over 35 years of experience in damage analysis and simulation
Combination of FEM and CFD methods as well as multiphysics for precise results
Analysis, optimization, and verification from a single source
Fast results – often within a few days
Trusted by leading industrial companies
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Damage analysis with Merkle CAE Solutions
This is how the collaboration works
To ensure you know what to expect, we make our collaboration transparent and efficient:
1. Initial consultation & data review
2. Simulation & damage analysis (FEM/CFD)
3. Report & recommendations for action
4. Optimization & verification
